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ft Service Source 




PowerBook G4 (lGHz/867MHz) 

November 6, 2002 



© 2002 Apple Computer, Inc. All rights reserved. 



I Service Source 




Take Apart 



PowerBook G4 (lGHz/867MHz) 



© 2002 Apple Computer, Inc. All rights reserved. 



PowerBook G4 (lGHz/867MHz) 



Keyboard 
Replacement Instructions 



Follow the instructions in this sheet carefully. Failure to follow these instructions could 
damage your equipment and void its warranty. 

Note: Written and video instructions covering customer-installable parts are available at 
http://www.info.apple.com/installparts/. 

Warning: During this procedure, keep small parts away from children. 

Tools Required 

The only tool required for this procedure is a jeweler's flat-blade screwdriver 
(if keyboard is locked). 

Removing the Installed Keyboard 

Warning: Always shut down your computer before opening it to avoid damaging its 
internal components or causing injury. After you shut down the computer, the 
internal components can be very hot. Let the computer cool down before 
continuing. 

1 . Place your computer on a clean, flat surface. 

2. Shut down your computer and wait thirty minutes before continuing. 

3. Disconnect the power cord and any other cables connected to the computer. 



4. Close the computer and turn it over. 

5. Slide the battery latch (Figure 1 A) to the right to remove the battery (Figure 1B). 

Removing the battery will prevent you from accidentally turning on the computer. 

Warning: Removing the battery before shutting down your computer may 
result in data loss. 

Figure 1 




6. Turn over the computer. 

7. Raise the display so you can access the keyboard. 

8. Make sure the keyboard locking screw, located in the small plastic tab to the left of the 
Num Lock key (Figure 2), is not in the locked position. Your PowerBook comes with 
the keyboard unlocked, so unless you or someone else locked the keyboard, you can 
skip this step. 

To unlock the keyboard, turn the screw 1/2 turn. 

Figure 2 




PowerBook G4 (1GHz/867MHz) Keyboard - 2 



9. Release the keyboard by pulling down on the keyboard release tabs (located to the left 
of the F1 and F12 keys) (Figure 3), then lift the top portion of the keyboard up slightly, 
and toward the display. 

Figure 3 




10. Flip the keyboard over and lay it on the palm rests and trackpad. (Figure 4) 
Figure 4 




PowerBook G4 (1GHz/867MHz) Keyboard - 3 



1 1 . Touch the computer's inside framework (a dull gray conductive composite material) to 
discharge any static electricity, as shown (Figure 5). 

Important: To avoid electrostatic discharge damage, always ground yourself by 
touching the computer's framework before you touch any parts or install any 
components inside the computer. To avoid static electricity building back up in your 
body, do not walk around the room until you have completed your installation and 
closed the computer. 

Figure 5 




12. Locate the keyboard cable connector. (Figure 6) 
Figure 6 

II 




1 3. Pull up on the connector, from side to side if needed, to disconnect it from the computer. 

14. Set the keyboard aside. 

PowerBook G4 (1GHz/867MHz) Keyboard - 4 



Installing the Replacement Keyboard 

1 . Lay the replacement keyboard in the correct orientation over the keyboard opening, 
then flip it toward you and lay it face down on the palm rests and trackpad to expose its 
connector cable. (Figure 7) 

Figure 7 




2. Firmly insert the keyboard cable connector into its connector on the computer. 

3. Flip the keyboard back toward the keyboard opening in the case. 

4. Hold the keyboard at an angle and insert the tabs on the bottom edge of the keyboard 
into the slots below the edge of the keyboard opening. (Figure 8) 

Important: Make sure that all the tabs are seated and that the keyboard rests flush 
against the edge of the opening. 

Figure 8 




PowerBook G4 (1GHz/867MHz) Keyboard - 5 



5. Lay the keyboard flat into the keyboard opening. 

6. Pull down on the keyboard release tabs while pressing down on the top portion of the 
keyboard (Figure 9). Release the tabs to secure the keyboard in place. 

Figure 9 




7. Close the display and turn the PowerBook over. 

8. Replace the battery. (Figure 1 0) 

Important: Make sure that the battery locks securely into place and that the battery 
latch is slid all the way into the locked position. 

Figure 10 




9. Reconnect the power cord and any other cables that were connected, and restart your 
computer. 

Warning: Never turn on your computer unless all of its internal and external 
parts are in place and it is closed. Operating the computer when it is open or 
missing parts can damage your computer or cause injury. 



PowerBook G4 (1GHz/867MHz) Keyboard - 6 



• Apple Computer, Inc. 

© 2002 Apple Computer, Inc. All rights reserved. 

This document is protected under U.S. Copyright Law and International Treaties, and no 
part of this document may be reproduced in any form without written permission from 
Apple. 

Apple is not responsible for typographical, printing, or inadvertent errors. 

Apple Computer, Inc. 

1 Infinite Loop 

Cupertino, CA 95014-2084 

USA 

+ 1 408 996 1010 

http://www.apple.com 

Apple, the Apple logo, and PowerBook are trademarks of Apple Computer, Inc., registered 
in the U.S. and other countries. 



PowerBook G4 (1GHz/867MHz) Keyboard - 7 



PowerBook G4 (lGHz/867MHz) 



Memory Card 
Replacement Instructions 



Follow the instructions in this sheet carefully. Failure to follow these instructions could 
damage your equipment and void its warranty. 

Note: Written and video instructions covering customer-installable parts are available at 
http://www.info.apple.com/installparts/. 

Warning: During this procedure, keep small parts away from children. 

Tools Required 

The only tool required for this procedure is a jeweler's flat-blade screwdriver 
(if keyboard is locked). 

Opening the Computer 

Warning: Always shut down your computer before opening it to avoid damaging its 
internal components or causing injury. After you shut down the computer, the 
internal components can be very hot. Let the computer cool down before 
continuing. 

1 . Place your computer on a clean, flat surface. 

2. Shut down your computer and wait thirty minutes before continuing. 

3. Disconnect the power cord and any other cables connected to the computer. 



4. Close the computer and turn it over. 

5. Slide the battery latch (Figure 1 A) to the right to remove the battery (Figure 1B). 

Removing the battery will prevent you from accidentally turning on the computer. 

Warning: Removing the battery before shutting down your computer may 
result in data loss. 

Figure 1 




6. Turn over the computer. 

7. Raise the display so you can access the keyboard. 

8. Make sure the keyboard locking screw, located in the small plastic tab to the left of the 
Num Lock key (Figure 2), is not in the locked position. Your PowerBook comes with 
the keyboard unlocked, so unless you or someone else locked the keyboard, you can 
skip this step. 

To unlock the keyboard, turn the screw 1/2 turn. 

Figure 2 




PowerBook G4 (1GHz/867MHz) Memory - 2 



9. Release the keyboard by pulling down on the keyboard release tabs (located to the left 
of the F1 and F12 keys) (Figure 3), then lift the top portion of the keyboard up slightly, 
and toward the display. 

Figure 3 




10. Flip the keyboard over and lay it on the palm rests and trackpad. (Figure 4) 
Figure 4 




PowerBook G4 (1GHz/867MHz) Memory - 3 



1 1 . Touch the computer's inside framework (a dull gray conductive composite material) to 
discharge any static electricity, as shown (Figure 5). 

Important: To avoid electrostatic discharge damage, always ground yourself by 
touching the computer's framework before you touch any parts or install any 
components inside the computer. To avoid static electricity building back up in your 
body, do not walk around the room until you have completed your installation and 
closed the computer. 

Figure 5 




Removing the Installed Memory Card 

1 . To remove a memory card, locate the brackets that secure the card on both sides 
(Figure 6). Carefully spread the brackets apart until the card releases on each side. 
Pull the card up and out. 

Note: If there is a memory card in the upper memory slot (Figure 6A), it must be 
removed before removing a card in the lower slot (Figure 6B). 

Figure 6 




PowerBook G4 (1GHz/867MHz) Memory - 4 



Installing the Replacement Memory Card 

Warning: When handling a memory card, do not touch its gold connectors. Handle 
the card only by the edges. 

1 . To install the memory card, line up the notch in the card with the small tab in the 
memory slot. Hold the card at a 30-degree angle (Figure 7 A), and then push the card 
into the slot until it is firmly seated. 

Note: You may feel some resistance. If you are having trouble inserting the card, try 
pushing one side at a time. 

Figure 7 




2. Gently push the card down until the two brackets on either side of the card lock into 
place (Figure 8). 

Figure 8 




PowerBook G4 (1GHz/867MHz) Memory - 5 



Closing the Computer 

1 . Flip the keyboard back toward the keyboard opening in the case. 

2. Hold the keyboard at an angle and insert the tabs on the bottom edge of the keyboard 
into the slots below the edge of the keyboard opening. (Figure 9) 

Important: Make sure that all the tabs are seated and that the keyboard rests flush 
against the edge of the opening. 

Figure 9 




3. Lay the keyboard flat into the keyboard opening. 

4. Pull down on the keyboard release tabs while pressing down on the top portion of the 
keyboard (Figure 10). Release the tabs to secure the keyboard in place. 

Figure 10 




5. Close the display and turn the PowerBook over. 



PowerBook G4 (1GHz/867MHz) Memory - 6 



6. Replace the battery. (Figure 11) 

Important: Make sure that the battery locks securely into place and that the battery 
latch is slid all the way into the locked position. 

Figure 11 




7. Reconnect the power cord and any other cables that were connected, and restart your 
computer. 

Warning: Never turn on your computer unless all of its internal and external 
parts are in place and it is closed. Operating the computer when it is open or 
missing parts can damage your computer or cause injury. 



m Apple Computer, Inc. 

© 2002 Apple Computer, Inc. All rights reserved. 

This document is protected under U.S. Copyright Law and International Treaties, and no 
part of this document may be reproduced in any form without written permission from 
Apple. 

Apple is not responsible for typographical, printing, or inadvertent errors. 

Apple Computer, Inc. 

1 Infinite Loop 

Cupertino, CA 95014-2084 

USA 

+ 1 408 996 1010 

http://www.apple.com 

Apple, the Apple logo, and PowerBook are trademarks of Apple Computer, Inc., registered 
in the U.S. and other countries. 



PowerBook G4 (1GHz/867MHz) Memory - 7 



PowerBook G4 (lGHz/867MHz) 



Bottom Case 
Replacement Instructions 



Follow the instructions in this sheet carefully. Failure to follow these instructions could 
damage your equipment and void its warranty. 

Note: Written and video instructions covering customer-installable parts are available at 
http://www.info.apple.com/installparts/. 

Warning: Sharp edges can exist inside your computer and on any parts being 
removed or installed. Use caution to avoid injury. 

During this procedure, keep small parts away from children. 

Tools Required 

• Soft towel or cloth, larger than the PowerBook 

• Torx T8 screwdriver 



Removing the Bottom Case 

Warning: Always shut down your computer before opening it to avoid damaging its 
internal components or causing injury. After you shut down the computer, the 
internal components can be very hot. Let the computer cool down before 
continuing. 

1 . Place your computer on a clean, flat surface. 

2. Shut down your computer and wait thirty minutes before continuing. 

3. Disconnect the power cord and any other cables connected to the computer. 



4. Place a towel or soft cloth on a table in front of you. (Figure 1 A) 

The towel or cloth will protect the keyboard and display area of the PowerBook when 
you flip it over to remove the battery and bottom case. Make sure it covers an area 
large enough for your PowerBook and that it hangs over the edge of the table. 

5. With the display open at an angle greater than 90 degrees, carefully flip the 
PowerBook over and lay it flat, fully on the table. Make sure the display hangs over the 
edge of the table and rests lightly on your lap. (Figure 1B) 

Important: Do not open the display farther than the angle shown. 




6. Remove the battery by sliding the battery latch to the left. Make sure to return the latch 
fully to the right. (Figure 2) 

Removing the battery will prevent you from accidentally turning on the computer. 

Warning: Removing the battery before shutting down your computer may 
result in data loss. 

Figure 2 




PowerBook G4 (1GHz/867MHz) Bottom Case - 2 



7. Use a Torx T8 screwdriver to remove the seven bottom case screws in the order 
shown. (Figure 3) 

Important: To avoid damaging the case, be careful that the screwdriver tip does not 
slip out of the screw head during removal. 

Figure 3 




Note: In the following two steps you will disengage the left and right sides of the bottom 
case and then pivot it forward to remove. 

8. Carefully slide the bottom case away from you. (Figure 4) 

Important: Do not push on the rubber feet of the bottom case. 
Figure 4 




PowerBook G4 (1GHz/867MHz) Bottom Case - 3 



9. Pivot the bottom case up as shown. (Figure 5) 
Figure 5 




Installing the Replacement Bottom Case 

1 . To attach the new bottom case, align the notches on the right and left sides of the 
case, then press down slightly to secure the case. Check the alignment of the seven 
screw holes to make sure the bottom case is properly positioned. 

Important: Make sure that the seams between the bottom case and the frame are 
closed. Check the outside edges and around the battery well. Verify that the 
alignment tab on the underside of the bottom case (Figure 6A) has seated, and the 
case lies flat. 

2. Replace the seven screws in the order shown. (Figure 6) 

Note: The screws must go in straight and easily; if they do not, readjust the bottom 
case for proper alignment. Do not overtighten the screws or damage could result. 

Important: To avoid damaging the case, be careful that the screwdriver tip does not 
slip out of the screw head during tightening. 

Figure 6 




PowerBook G4 (1GHz/867MHz) Bottom Case - 4 



3. Replace the battery. (Figure 7) 

Important: Make sure that the battery locks securely into place and that the battery 
latch is slid all the way into the locked position. 

Figure 7 




4. Turn the computer over. Look at the optical drive slot to make sure that the case is 
properly secured. If a gap exists below the slot, gently pull the bottom of the optical 
drive slot toward you until it clicks into place and the gap is removed. (Figure 8) 

Figure 8 




5. Reconnect the power cord and any other cables that were connected, and restart your 
computer. 

Warning: Never turn on your computer unless all of its internal and external 
parts are in place and it is closed. Operating the computer when it is open or 
missing parts can damage your computer or cause injury. 



PowerBook G4 (1GHz/867MHz) Bottom Case - 5 



• Apple Computer, Inc. 

© 2002 Apple Computer, Inc. All rights reserved. 

This document is protected under U.S. Copyright Law and International Treaties, and no 
part of this document may be reproduced in any form without written permission from 
Apple. 

Apple is not responsible for typographical, printing, or inadvertent errors. 

Apple Computer, Inc. 

1 Infinite Loop 

Cupertino, CA 95014-2084 

USA 

+ 1 408 996 1010 

http://www.apple.com 

Apple, the Apple logo, and PowerBook are trademarks of Apple Computer, Inc., registered 
in the U.S. and other countries. 



PowerBook G4 (1GHz/867MHz) Bottom Case - 6 



PowerBook G4 (lGHz/867MHz) 



AirPort Card 
Replacement Instructions 



Follow the instructions in this sheet carefully. Failure to follow these instructions could 
damage your equipment and void its warranty. 

Note: Written and video instructions covering customer-installable parts are available at 
http://www.info.apple.com/installparts/. 

Warning: Sharp edges can exist inside your computer and on any parts being 
removed or installed. Use caution to avoid injury. 

During this procedure, keep small parts away from children. 

Tools Required 

• Soft towel or cloth, larger than the PowerBook 

• Torx T8 screwdriver 



Opening the Computer 

Warning: Always shut down your computer before opening it to avoid damaging its 
internal components or causing injury. After you shut down the computer, the 
internal components can be very hot. Let the computer cool down before 
continuing. 

To access the AirPort Card, you must first remove the battery and bottom case. 

1 . Place your computer on a clean, flat surface. 

2. Shut down your computer and wait thirty minutes before continuing. 

3. Disconnect the power cord and any other cables connected to the computer. 



4. Place a towel or soft cloth on a table in front of you. (Figure 1 A) 

The towel or cloth will protect the keyboard and display area of the PowerBook when 
you flip it over to remove the battery and bottom case. Make sure it covers an area 
large enough for your PowerBook and that it hangs over the edge of the table. 

5. With the display open at an angle greater than 90 degrees, carefully flip the 
PowerBook over and lay it flat, fully on the table. Make sure the display hangs over the 
edge of the table and rests lightly on your lap. (Figure 1B) 

Important: Do not open the display farther than the angle shown. 




6. Remove the battery by sliding the battery latch to the left. Make sure to return the latch 
fully to the right. (Figure 2) 

Removing the battery will prevent you from accidentally turning on the computer. 

Warning: Removing the battery before shutting down your computer may 
result in data loss. 

Figure 2 




PowerBook G4 (1GHz/867MHz) AirPort Card- 2 



7. Use a Torx T8 screwdriver to remove the seven bottom case screws in the order 
shown. (Figure 3) 

Important: To avoid damaging the case, be careful that the screwdriver tip does not 
slip out of the screw head during removal. 

Figure 3 




Note: In the following two steps you will disengage the left and right sides of the bottom 
case and then pivot it forward to remove. 

8. Carefully slide the bottom case away from you. (Figure 4) 

Important: Do not push on the rubber feet of the bottom case. 
Figure 4 




PowerBook G4 (1GHz/867MHz) AirPort Card- 3 



9. Pivot the bottom case up as shown. (Figure 5) 
Figure 5 




10. Touch the computer's inside framework (a dull gray conductive composite material) to 
discharge any static electricity, as shown. (Figure 6) 

Important: To avoid electrostatic discharge damage, always ground yourself by 
touching the computer's framework before you touch any parts or install any 
components inside the computer. To avoid static electricity building back up in your 
body, do not walk around the room until you have completed your installation and 
closed the computer. 

Figure 6 




PowerBook G4 (1GHz/867MHz) AirPort Card- 4 



Removing the Installed AirPort Card 

1 . Pull back on the antenna clip (Figure 7A) to release the antenna cable connector 
(Figure 7B) and allow the card to rise up slightly. 

2. Pull the card from the AirPort connector (Figure 7D). 

3. If there is tape securing the antenna cable to the AirPort Card, carefully remove it and 
store it in the battery compartment for reuse later. When installing the replacement 
AirPort Card, use the tape to secure the cable in the same manner. 

4. To disconnect the antenna cable connector, hold the AirPort Card with one hand and 
grasp the antenna cable connector with the other. While being careful not to strain the 
antenna cable (Figure 7C), firmly pull the connector straight out of the AirPort Card. 

Figure 7 




Important: If reassembling the computer without an AirPort Card, replace the 
antenna cable connector into its holder (Figure 9B) and pull the loop of the antenna 
cable up slightly and away from the edge of the computer case. This prevents the 
cable from interfering with the PC card slot, below, or getting pinched during 
reassembly. 

Also, if the AirPort Card connector (Figure 7D) is rotated up, push it down into the 
level position. This allows the bottom case to install properly. 



PowerBook G4 (1GHz/867MHz) AirPort Card- 5 



Installing the Replacement AirPort Card 

1 . If the replacement AirPort Card came with the AirPort adapter (Figure 8A), remove 
the metal clip (Figure 8B) and pull the AirPort Card (Figure 8C) from the adapter. 
(The adapter and metal clip are not used with your PowerBook.) 

Figure 8 




—-A 



-— B 

I 

2. If necessary, pull the AirPort antenna cable connector (Figure 9A) from its holder 
(Figure 9B). 

Figure 9 




3. Position the AirPort Card (Figure 10B) with the AirPort ID numbers and bar code 
facing up. Pull up the insertion end of the AirPort Card connector (Figure 10A) slightly 
and slide the card all the way into the connector until it is securely attached. 

Figure 10 

A 




PowerBook G4 (1GHz/867MHz) AirPort Card- 6 



4. Plug the antenna cable connector (Figure 1 1 A) into the port on the AirPort Card, 
located just below the plastic tab (Figure 1 1 B). Make sure the connector is straight 
before inserting it into the port. 

Note: If tape was removed earlier, use it to secure the antenna cable to the card. 

5. Push the AirPort Card down until the antenna cable connector is secured by the small 
antenna clip (Figure 1 1 C). 

Important: Route the antenna cable (Figure 11D) between the edge of the computer 
and the AirPort Card. Verify that the cable is away from the edge of the computer so 
that it will not be pinched during reassembly and that it does not sag down into the 
PC card slot area (below the AirPort Card). Take up any extra cable by tucking it in 
where shown (Figure 11E). 

6. Fold the plastic tab (Figure 1 1 B) on the AirPort Card over the top of the card. 

Note: The plastic tab must be folded over the card during the installation of the 
bottom case; otherwise you will not be able to securely attach the bottom case to the 
computer. 

Figure 11 




PowerBook G4 (1GHz/867MHz) AirPort Card- 7 



Closing the Computer 

1 . To attach the bottom case, align the notches on the right and left sides of the case, 
then press down slightly to secure the case. Check the alignment of the seven screw 
holes to make sure the bottom case is properly positioned. 

Important: Make sure that the seams between the bottom case and the frame are 
closed. Check the outside edges and around the battery well. Verify that the 
alignment tab on the underside of the bottom case (Figure 12A) has seated, and the 
case lies flat. 

2. Replace the seven screws in the order shown. (Figure 12) 

Note: The screws must go in straight and easily; if they do not, readjust the bottom 
case for proper alignment. Do not overtighten the screws or damage could result. 

Important: To avoid damaging the case, be careful that the screwdriver tip does not 
slip out of the screw head during tightening. 

Figure 12 



PowerBook G4 (1GHz/867MHz) AirPort Card- 8 



3. Replace the battery. (Figure 13) 

Important: Make sure that the battery locks securely into place and that the battery 
latch is slid all the way into the locked position. 

Figure 13 




4. Turn the computer over. Look at the optical drive slot to make sure that the case is 
properly secured. If a gap exists below the slot, gently pull the bottom of the optical 
drive slot toward you until it clicks into place and the gap is removed. (Figure 14) 

Figure 14 




5. Reconnect the power cord and any other cables that were connected, and restart your 
computer. 

Warning: Never turn on your computer unless all of its internal and external 
parts are in place and it is closed. Operating the computer when it is open or 
missing parts can damage your computer or cause injury. 

PowerBook G4 (1GHz/867MHz) AirPort Card- 9 



• Apple Computer, Inc. 

© 2002 Apple Computer, Inc. All rights reserved. 

This document is protected under U.S. Copyright Law and International Treaties, and no 
part of this document may be reproduced in any form without written permission from 
Apple. 

Apple is not responsible for typographical, printing, or inadvertent errors. 

Apple Computer, Inc. 

1 Infinite Loop 

Cupertino, CA 95014-2084 

USA 

+ 1 408 996 1010 

http://www.apple.com 

Apple, the Apple logo, and PowerBook are trademarks of Apple Computer, Inc., registered 
in the U.S. and other countries. 



PowerBook G4 (1GHz/867MHz) AirPort Card- 10 



PowerBook G4 (lGHz/867MHz) 



Hard Drive 
Replacement Instructions 



Follow the instructions in this sheet carefully. Failure to follow these instructions could 
damage your equipment and void its warranty. 

Note: Written and video instructions covering customer-installable parts are available at 
http://www.info.apple.com/installparts/. 

Warning: Sharp edges can exist inside your computer and on any parts being 
removed or installed. Use caution to avoid injury. 

During this procedure, keep small parts away from children. 

Tools Required 

• Soft towel or cloth, larger than the PowerBook 

• Torx T8 screwdriver (provided with hard drive) 

Backing Up Your Data 

Warning: Before replacing your hard drive, make sure you back up all data on the 
drive. 

Opening the Computer 

Warning: Always shut down your computer before opening it to avoid damaging its 
internal components or causing injury. After you shut down the computer, the 
internal components can be very hot. Let the computer cool down before 
continuing. 

To access the hard drive, you must first remove the battery and bottom case. 

1 . Place your computer on a clean, flat surface. 

2. Shut down your computer and wait thirty minutes before continuing. 

3. Disconnect the power cord and any other cables connected to the computer. 



4. Place a towel or soft cloth on a table in front of you. (Figure 1 A) 

The towel or cloth will protect the keyboard and display area of the PowerBook when 
you flip it over to remove the battery and bottom case. Make sure it covers an area 
large enough for your PowerBook and that it hangs over the edge of the table. 

5. With the display open at an angle greater than 90 degrees, carefully flip the 
PowerBook over and lay it flat, fully on the table. Make sure the display hangs over the 
edge of the table and rests lightly on your lap. (Figure 1B) 

Important: Do not open the display farther than the angle shown. 




6. Remove the battery by sliding the battery latch to the left. Make sure to return the latch 
fully to the right. (Figure 2) 

Removing the battery will prevent you from accidentally turning on the computer. 

Warning: Removing the battery before shutting down your computer may 
result in data loss. 

Figure 2 




PowerBook G4 (1GHz/867MHz) Hard Drive - 2 



7. Use a Torx T8 screwdriver to remove the seven bottom case screws in the order 
shown. (Figure 3) 

Important: To avoid damaging the case, be careful that the screwdriver tip does not 
slip out of the screw head during removal. 

Figure 3 




Note: In the following two steps you will disengage the left and right sides of the bottom 
case and then pivot it forward to remove. 

8. Carefully slide the bottom case away from you. (Figure 4) 

Important: Do not push on the rubber feet of the bottom case. 
Figure 4 




PowerBook G4 (1GHz/867MHz) Hard Drive - 3 



9. Pivot the bottom case up as shown. (Figure 5) 
Figure 5 




10. Touch the computer's inside framework (a dull gray conductive composite material) to 
discharge any static electricity, as shown. (Figure 6) 

Important: To avoid electrostatic discharge damage, always ground yourself by 
touching the computer's framework before you touch any parts or install any 
components inside the computer. To avoid static electricity building back up in your 
body, do not walk around the room until you have completed your installation and 
closed the computer. 

Figure 6 




PowerBook G4 (1GHz/867MHz) Hard Drive - 4 



Removing the Installed Hard Drive 

1 . With your fingers, carefully pry up the hard drive cable connector (Figure 7A) at its 
sides to disconnect it from the logic board. You may need to pry one side, then the 
other, in a rocking motion. 

Figure 7 




2. With a Torx T8 screwdriver, remove the two screws that secure the hard drive 
mounting bracket, and remove the bracket. (Figure 8) 

Figure 8 




PowerBook G4 (1GHz/867MHz) Hard Drive - 5 



3. Pull up on the right side of the hard drive to remove it. (Figure 9) 

Important: The hard drive connector cable can be carefully used to help remove the 
hard drive if it lifts easily. Do not pull hard on the connector cable. 

Figure 9 




Note: There are four rubber stoppers on the hard drive that fit over screws (two on 
each side). Remove any that may have fallen off or that remain in the holes in the 
mounting bracket inside the computer. 

4. If not included with the replacement drive, remove the Mylar sheath and the flex cable 
to transfer to the replacement drive. 

Important: The connector pins on the hard drive are fragile and bend easily. Use 
care to keep the pins straight when removing or installing the flex cable. 



PowerBook G4 (1GHz/867MHz) Hard Drive - 6 



Installing the Replacement Hard Drive 

Warning: To avoid potential injury or damage, avoid touching the thin strip of metal 
that extends up from the rib frame at the battery well. 

Important: Avoid touching the optical drive as you perform this procedure. 

1 . Make sure that the screws (Figure 10A) and rubber stoppers (Figure 10B) are in 

place on the sides of the replacement drive. 

2. Install the Mylar sheath (Figure 10C) so that it covers the bottom and left and right 
sides of the drive. The sheath is directional and must be installed in the direction that 
does not extend beyond the front of the drive. 

3. Carefully install the hard drive cable, if needed, (Figure 10D).The cable connector is 
keyed to fit only one way. 

Figure 10 




4. Insert the left side of the drive first, then the right. Use a screwdriver through the frame 
holes on the left side to help align the stoppers, as necessary. (Figure 11) 

Figure 11 




PowerBook G4 (1GHz/867MHz) Hard Drive - 7 



5. Replace the hard drive mounting bracket and secure with the screws. (Figure 12) 

Important: Check that the rubber stoppers and Mylar sheath are not pinched by the 
bracket. 

Figure 12 



6. Connect the hard drive cable connector (Figure 13) to the logic board. 
Figure 13 



PowerBook G4 (1GHz/867MHz) Hard Drive - 8 



Closing the Computer 

1 . To attach the bottom case, align the notches on the right and left sides of the case, 
then press down slightly to secure the case. Check the alignment of the seven screw 
holes to make sure the bottom case is properly positioned. 

Important: Make sure that the seams between the bottom case and the frame are 
closed. Check the outside edges and around the battery well. Verify that the 
alignment tab on the underside of the bottom case (Figure 14A) has seated, and the 
case lies flat. 

2. Replace the seven screws in the order shown. (Figure 14) 

Note: The screws must go in straight and easily; if they do not, readjust the bottom 
case for proper alignment. Do not overtighten the screws or damage could result. 

Important: To avoid damaging the case, be careful that the screwdriver tip does not 
slip out of the screw head during tightening. 

Figure 14 



PowerBook G4 (1GHz/867MHz) Hard Drive - 9 



3. Replace the battery. (Figure 15) 

Important: Make sure that the battery locks securely into place and that the battery 
latch is slid all the way into the locked position. 

Figure 15 




4. Turn the computer over. Look at the optical drive slot to make sure that the case is 
properly secured. If a gap exists below the slot, gently pull the bottom of the optical 
drive slot toward you until it clicks into place and the gap is removed. (Figure 16) 

Figure 16 




PowerBook G4 (1GHz/867MHz) Hard Drive - 10 



5. Reconnect the power cord and any other cables that were connected, and restart your 
computer. 

Warning: Never turn on your computer unless all of its internal and external 
parts are in place and it is closed. Operating the computer when it is open or 
missing parts can damage your computer or cause injury. 

6. Restore the data from your backup to the new drive. 

7. Check the operation of the optical drive. If the hard drive is installed incorrectly, the 
optical drive mechanism might not spin correctly and will result in mechanical noise 
when playing a disc. 



• Apple Computer, Inc. 

© 2002 Apple Computer, Inc. All rights reserved. 

This document is protected under U.S. Copyright Law and International Treaties, and no 
part of this document may be reproduced in any form without written permission from 
Apple. 

Apple is not responsible for typographical, printing, or inadvertent errors. 

Apple Computer, Inc. 

1 Infinite Loop 

Cupertino, CA 95014-2084 

USA 

+ 1 408 996 1010 

http://www.apple.com 

Apple, the Apple logo, and PowerBook are trademarks of Apple Computer, Inc., registered 
in the U.S. and other countries. 



PowerBook G4 (1GHz/867MHz) Hard Drive - 11 



PowerBook G4 (lGHz/867MHz) 



Modem Filter Board 
Replacement Instructions 



The following instructions explain how to replace the modem EMI filter board in the 
PowerBook G4 (1GHz/867MHz) computer. 

Tools 

• Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool 

• Torx T8 screwdriver 



Preliminary Steps 

Before you begin, remove the following: 

• Battery 

• Keyboard 



' 2002 Apple Computer, Inc. All rights reserved. 



Procedure 

1 . Disconnect the RJ-1 1 and the modem wire connectors from the modem filter board. 

2. Remove the Torx T8 screw. 







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i 



3. Guide the modem filter board out of the case. 



PowerBook G4 (1GHz/867MHz) Modem Filter Board - 2 



PowerBook G4 (lGHz/867MHz) 



DC-In Board 
Replacement Instructions 



The following instructions explain how to replace the DC-in board in the PowerBook G4 
(1GHz/867MHz) computer. 

Tools 

• Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool 

• Torx T6 screwdriver 



Preliminary Steps 

Before you begin, remove the following: 

• Battery 

• Bottom case 



' 2002 Apple Computer, Inc. All rights reserved. 



Procedure 

1 . Disconnect the DC-in board cable connector from the logic board. 

2. Remove the two Torx T6 screws. 

Note: The screw holding the fan securing tab may be longer than the other. 





3. Guide the DC-in board out of the case. 

Replacement Note: When replacing the DC-in board, ensure that the secondary fan's 
securing-tab rests on top of the board, and that the fan's bracket seats properly over the 
pin on the rib frame. If one screw was longer, replace it at the fan's securing-tab side. 

If you performed a procedure that also removed the logic board, ensure that the power 
button cable routes up and left, toward the center of the top case, under the DC-in board. 




Replacement Note: Make sure that the DC connector is straight and centered in the port 
opening. With the power adapter unplugged, the adapter connector may be inserted onto 
the DC connector to ensure that the connector is centered and straight before securing the 
DC-in board. 



PowerBook G4 (1GHz/867MHz) DC-ln Board - 2 



PowerBook G4 (lGHz/867MHz) 



Inverter Board 
Replacement Instructions 



The following instructions explain how to replace the inverter board in the PowerBook G4 
(1GHz/867MHz) computer. 

Tools 

• Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool 

• Torx T6 screwdriver 



Preliminary Steps 

Before you begin, remove the following: 

• Battery 

• Bottom case 



' 2002 Apple Computer, Inc. All rights reserved. 



Procedure 

Important: With the bottom case removed, be careful if turning over the computer. Some 
components could become loose and fall out. 

1 . Disconnect the inverter board flex cable from both the inverter board and logic board. 




2. Disconnect the bulb wire cable from the inverter board. 

3. Remove the two T6 screws that secure the inverter board and remove the board. 

Replacement Note: When reinstalling the replacement optical drive, ensure that the bulb 
wire cable is safely within the case edge so that it will not get pinched by the bottom case. 




PowerBook G4 (1GHz/867MHz) Inverter Board - 2 



4. Install the replacement inverter board onto the optical drive. 

5. Reassemble and test the computer. 

Important: Make sure the bottom case is installed correctly. If the slot-load area is 
slightly bowed, carefully pull the bottom edge of the slot until it clicks into place and 
becomes flush with the bottom case. 




{ 



/ 








Important: Check the operation of the optical drive. If the drive is installed 
incorrectly, the optical drive mechanism might not spin correctly and will result in 
mechanical noise when playing a disc. 



PowerBook G4 (1GHz/867MHz) Inverter Board - 3 



PowerBook G4 (lGHz/867MHz) 



Modem 

Replacement Instructions 



The following instructions explain how to replace the modem in the PowerBook G4 (1GHz/ 
867MHz) computer. 

Tools 

• Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool 

• Torx T6 screwdriver 

• Torx T8 screwdriver 



Preliminary Steps 

Before you begin, remove the following: 

• Battery 

• Keyboard 

• Bottom case (remove in step 2) 



' 2002 Apple Computer, Inc. All rights reserved. 



Procedure 

1 . With the display open and the keyboard removed, locate and remove the EMI clip that 
secures the optical drive's flex cable to the rib frame. Side until reassembling the 
computer. 

Replacement Note: When reassembling the computer, ensure that the EMI clip 
captures the tab on the flex cable and holds it against the rib frame. 




2. Remove the bottom case. 

Important: With the bottom case removed, be careful if turning over the computer. 
Some components could become loose and fall out. 

3. Remove the two T8 screws that secure the hard drive mounting bracket and remove 
the bracket. 




PowerBook G4 (1GHz/867MHz) Modem - 2 



4. Disconnect the inverter board flex cable from the inverter board and logic board. 

5. Disconnect the optical drive and modem flex cables from the logic board. 




6. Remove the two T6 screws that secure the modem. 

7. Lift up the end of the modem slightly and disconnect the 2-pin cable connector. 




PowerBook G4 (1GHz/867MHz) Modem - 3 



8. Use a thin tool to lift the optical drive slightly, then deroute the modem flex cable. 




9. If the modem flex cable is not damaged, remove it and transfer it to the replacement 
modem. 

10. Install the replacement modem. Avoid putting pressure on or stressing the modem 
board during installation. 

1 1 . To replace the optical drive, carefully guide the rubber stoppers on the outer side of 
the drive past the edge of the computer case. 

Warning: To prevent damage to the optical drive, handle the drive only by the 
corners. Do not press on the body of the drive. 

Important: When the rubber stoppers are inserted, push down on all four corners of 
the drive to verify that the drive is level and secure. 



PowerBook G4 (1GHz/867MHz) Modem - 4 



12. Reassemble and test the computer. 

Replacement Note: When reinstalling the optical drive, ensure that the bulb wire 
cable is safely within the case edge so that it will not get pinched by the bottom case. 




Important: Make sure the bottom case is installed correctly. If the slot-load area is 
slightly bowed, carefully pull the bottom edge of the slot until it clicks into place and 
becomes flush with the bottom case. 




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/ 



/ 





Important: Check the operation of the optical drive. If the drive is installed 
incorrectly, the optical drive mechanism might not spin correctly and will result in 
mechanical noise when playing a disc. 



PowerBook G4 (1GHz/867MHz) Modem - 5 



PowerBook G4 (lGHz/867MHz) 



DVD-ROM/CD-RW (Combo), 
DVD-R/CD-RW (Apple SuperDrive) 
Optical Drive 

Replacement Instructions 



The following instructions explain how to replace the combination DVD-ROM/CD-RW 
optical drive in the PowerBook G4 (1GHz/867MHz) computer. 

Tools 

• Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool 

• Torx T6 screwdriver 

• Torx T8 screwdriver 



Preliminary Steps 

Before you begin, remove the following: 

• Battery 

• Keyboard 

• Bottom case (remove in step 2) 



' 2002 Apple Computer, Inc. All rights reserved. 



Procedure 

1 . With the display open and the keyboard removed, locate and remove the EMI clip that 
secures the optical drive's flex cable to the rib frame. Set it aside for installation of the 
replacement drive. 

Replacement Note: When installing the replacement drive, ensure that the EMI clip 
captures the tab on the flex cable and holds it against the rib frame. 




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2. Remove the bottom case. 



Important: With the bottom case removed, be careful if turning over the computer. 
Some components could become loose and fall out. 



PowerBook G4 (1GHz/867MHz) DVD-R/CD-RW & DVD-ROM/CD-RW Optical Drive - 2 



3. Remove the two T8 screws that secure the hard drive mounting bracket and remove 
the bracket. 




4. Disconnect the inverter board flex cable from the inverter board and logic board. 

5. Disconnect the optical drive and modem flex cables from the logic board. 




PowerBook G4 (1GHz/867MHz) DVD-R/CD-RW & DVD-ROM/CD-RW Optical Drive - 3 



6. Disconnect the bulb wire cable from the inverter board. 

7. Remove the fourT6 screws that secure the modem and the inverter board and remove 
the inverter board. 

Replacement Note: When reinstalling the replacement optical drive, ensure that the bulb 
wire cable is safely within the case edge so that it will not get pinched by the bottom case. 




8. Lift up the end of the modem slightly and disconnect the 2-pin cable connector. 




PowerBook G4 (1GHz/867MHz) DVD-R/CD-RW & DVD-ROM/CD-RW Optical Drive - 4 



9. Use a thin tool to lift the optical drive slightly, then deroute the modem flex cable. 




10. Warning: To prevent damage to the optical drive, handle the drive only by the 
corners. Do not press on the body of the drive. 

To remove the optical drive, pull the drive to the right, away from the hard drive, to 
release the long rubber stopper from the rib frame. 

1 1 . Important: If you notice that the felt strip for the slot-load area is torn or damaged, 
replace the felt strip with a new one before replacing the optical drive. Follow the 
instructions below to replace the felt strip: 

Locate the felt strip that came with the replacement drive. Before you remove the old 
felt strip, note the alignment of the felt strip over the slot-load area in the inner top 
case. 




PowerBook G4 (1GHz/867MHz) DVD-R/CD-RW & DVD-ROM/CD-RW Optical Drive - 5 



Peel off the felt strip from the inner top case. If there is any residual adhesive on the 
top case, rub it away. 




Apply the new felt strip to the slot-load area. Make sure the new felt strip lies flat. Use 
a black stick to run the length of the slot to make sure that the felt strip does not block 
any of the slot. 




12. Install the modem and inverter board onto the replacement optical drive. Again, 
handle the optical drive only by the corners. Do not press on the body of the drive. 

13. To install the replacement optical drive, first insert the longer stopper on the inner side 
of the drive into the opening on the rib frame. Ensure that the other inner stopper rests 
securely in its space on the frame. Then while holding the inner side of the drive in 
place, carefully guide the rubber stoppers on the outer side of the drive past the edge 
of the computer case. 




Important: When the rubber stoppers are inserted, push down on all four corners of 
the drive to verify that the drive is level and secure. 



PowerBook G4 (1GHz/867MHz) DVD-R/CD-RW & DVD-ROM/CD-RW Optical Drive - 6 



14. Reassemble and test the computer. 

Important: Make sure the bottom case is installed correctly. If the slot-load area is 
slightly bowed, carefully pull the bottom edge of the slot until it clicks into place and 
becomes flush with the bottom case. 




Important: Check the operation of the optical drive. If the drive is installed 
incorrectly, the optical drive mechanism might not spin correctly and will result in 
mechanical noise when playing a disc. 



PowerBook G4 (1GHz/867MHz) DVD-R/CD-RW & DVD-ROM/CD-RW Optical Drive - 7 



PowerBook G4 (lGHz/867MHz) 



Backup Battery 
Replacement Instructions 



The following instructions explain how to replace the backup battery in the PowerBook G4 
(1GHz/867MHz) computer. 

Tools 

• Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool 

Preliminary Steps 

Before you begin, remove the following: 

• Battery 

• Optical drive 



' 2002 Apple Computer, Inc. All rights reserved. 



Procedure 

1 . Disconnect the backup battery cable from the backup battery. 

Note: If the cable connector gets caught on the ridged area of the top case, use a 
black stick to raise up the backup battery and then disconnect the cable. 




2. Note: The backup battery is compressed between two thin plastic sheets. The battery 
is held in place with adhesive on the lower plastic sheet. 

Slide a black stick under and along the edge of the backup battery. Pry up the 
backup battery so that the entire battery — including the lower plastic sheet — is 
removed from the inner top case. 

Warning: The ridged area of the top case is sharp. 



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PowerBook G4 (1GHz/867MHz) Backup Battery - 2 



3. If there is any adhesive left on the surface of the inner top case, use a black stick to 
rub it away. Do not use solvents. 

Note: When installing the replacement backup battery, make sure the inner top case 
is clean and free of debris. 

4. Peel off the cover sheet from the bottom surface of the replacement backup battery to 
expose the adhesive. 

5. When positioning the replacement backup battery on the inner top case, make sure 
the battery fits within the ridged battery area of the inner top case. 




6. Install the replacement backup battery, and reassemble and test the computer. 



PowerBook G4 (1GHz/867MHz) Backup Battery - 3 



PowerBook G4 (lGHz/867MHz) 



Logic Board 
Replacement Instructions 



The following instructions explain how to replace the logic board in the PowerBook G4 
(1GHz/867MHz) computer. 

Tools 

• Torx T8 screwdriver 

• Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool 

• Razor blade 

• Needle nose pliers (optional) 

Note: To organize the screws you remove from the computer, use a tray with divided 
compartments (such as a plastic ice cube tray). 

Preliminary Steps 

Before you begin, remove the following: 

• Battery 

• Keyboard 

• Bottom case (remove in step 4) 

• AirPort Card (if installed) 



' 2002 Apple Computer, Inc. All rights reserved. 



Procedure 

1 . With the display open and the keyboard removed, remove the T8 screw near the heat 
pipe. 




2. Disconnect the PC card flex cable connector and the keyed battery connector. 

Important: If the battery connector has not been disconnected before, the keyed 
connector may be tight. If necessary, use a black stick or needle nose pliers to 
loosen one side of the connector and then the other side. Then insert the black stick 
under the cables to pry up and disconnect the connector. 




Replacement Note: When reassembling the computer, tuck down the battery cables 
so they do not get in the way when the keyboard is installed. 



PowerBook G4 (1GHz/867MHz) Logic Board - 2 



3. Disconnect the 3-pin backup battery connector from the logic board. 




4. Remove the bottom case. 

Important: With the bottom case removed, be careful when turning over the 
computer. Some components could become loose and fall out. 



PowerBook G4 (1GHz/867MHz) Logic Board - 3 



Warning: The thin cables connected to the LVDS (low voltage data signal) 
connector are extremely delicate. Do not pull or pinch the LVDS cables. Be 
especially careful when working near cables that attach to the display. If any of 
these cables are damaged, the entire display module must be replaced. 

At the left side of the logic board, disconnect the 2-pin sleep LED cable connector, 
the LVDS connector, and the 6-pin audio connector. 





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6. At the right side of the logic board, disconnect the 2-pin power button cable connector, 
the DC-in board cable connector, and the inverter board and modem flex cable 
connectors. 







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PowerBook G4 (1GHz/867MHz) Logic Board - 4 



7. Disconnect the trackpad, hard drive and optical drive flex cable connectors. 

Note: If tape is covering the trackpad connector, reserve the tape for installation of 
the replacement logic board. 




8. Remove the T8 screw on the edge of the logic board near the battery well. 

Important: Install this screw first when installing the replacement logic board. This 
screw helps the logic board align properly to the rib frame. 

9. Remove the T8 screw securing the PC card cage. 




PowerBook G4 (1GHz/867MHz) Logic Board - 5 



10. Remove the five identical (bronze colored) T8 screws. 

Note: When reassembling the computer, do not overtighten the screws. 




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1 1 . Grasp the logic board near the AirPort Card carrier and gently lift the board up, as 
shown below, being careful where it catches on ports, back panel mesh liner, and 
disconnected cables. 

If necessary, open the panel door and press on the ports to free the logic board from 
the back panel. 

Important: Lift the board just enough to access and disconnect the secondary fan's 
connector on the logic board before removing the board. 




PowerBook G4 (1GHz/867MHz) Logic Board - 6 



Note: When reassembling the computer, make sure the replacement logic board 
ports align completely with the openings in the back panel. 

Note: When positioning the replacement logic board into the computer, check that 
cables and connectors do not get caught under the board. Tilt the logic board toward 
the back panel, and place the following cables into the notches in the board: 

• Power switch cable (reapply tape over the cable, if applicable) 

• Sleep LED cable 

• LVDS cable 

• Audio cable 

12. Remove existing memory cards from the logic board for installation on the 

replacement logic board. Carefully spread the end brackets to allow the card to raise 
up, then pull out. 




13. Check that an AirPort card carrier and fan is on the replacement logic board. If not 
transfer them to the replacement logic board. 

Note: You will need to order a new primary fan to install on the replacement board. 




PowerBook G4 (1GHz/867MHz) Logic Board - 7 



14. Make sure the top of the replacement logic board includes the following items. If not, 
transfer these items from the original logic board to the replacement board: 

• U-shaped EMI clip between the FireWire and Ethernet ports 

• Spongy mesh EMI pads adhered to two USB ports, FireWire port, DVI-I port, and 
headphone port, (use an I/O EMI gasket kit) 

• RJ-11 port 



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15. Make sure the underside of the replacement logic board includes the following items: 
• Rectangular plastic shims around the chips shown 




PowerBook G4 (1GHz/867MHz) Logic Board - 8 



16. Check that the heat exchanger has three rectangular thermal interface pads in place. 
If the pads are missing or damaged, replace them if available, otherwise replace the 
heat exchanger. 

17. Important: If you have removed the logic board to access another part, and you will 
be placing the original logic board back in the computer, use a razor blade to gently 
scrape away any residual thermal transfer material from the heat exchanger and the 
microprocessor chip. 

Warning: When scraping away the thermal transfer material from the 
microprocessor chip, be careful not to nick the microprocessor chip. 

Apply new thermal transfer material to the microprocessor chip as described in the 
next step. 






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PowerBook G4 (1GHz/867MHz) Logic Board - 9 



18. On the replacement logic board, center new thermal transfer material over the epoxy 
cap on the microprocessor chip. Press it into place. 




19. Install the replacement logic board, and reassemble and test the computer. 

Replacement Note: When replacing the logic board, the RJ-1 1 cable and backup 
battery wire connectors must be routed, as shown below, so that they do not interfere 
with the logic board replacement and can later be accessed through the keyboard 
opening. 

Ensure that optical drive's flex cable has not been pulled out of the EMI clip, and that 
the clip still secures the tab on the flex cable to the rib frame. 




PowerBook G4 (1GHz/867MHz) Logic Board - 10 



PowerBook G4 (lGHz/867MHz) 



Primary Fan 
Replacement Instructions 



The following instructions explain how to replace the primary fan in the PowerBook G4 
(1GHz/867MHz) computer. 

Tools 

• Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool 

• Razor blade 

• Needle nose pliers 

Preliminary Steps 

Before you begin, remove the following: 

• Battery 

• Logic Board 



' 2002 Apple Computer, Inc. All rights reserved. 



Procedure 

1 . With the logic board removed from the computer, disconnect the fan connector from 
the logic board. 




2. Turn over the logic board, and locate the cone-shaped pin at the right corner of the 
fan. Pull the rubber pin tight. Use a razor blade to cut through the rubber pin. 




PowerBook G4 (1GHz/867MHz) Primary Fan - 2 



3. Turn over the logic board, and tilt up the fan to remove it completely from the logic 
board. 

Note: The fan is secured to the logic board by an adhesive lining on the sides of the 
bottom of the fan. If there is any adhesive stuck to the surface of the logic board, 
remove it by rubbing it away. Do not use solvents. 




4. When installing the replacement fan, first use a black stick to push the cone-shaped 
rubber pin into the hole on the logic board. (If necessary, use needle nose pliers to pull 
the rubber pin through to the other side of the logic board.) Then, peel away the 
protective cover from the adhesive that lines the sides of the fan. Align the fan over 
the logic board opening and press the fan into place. 

Important: Do not press on the center hub of the fan. Press only on the outside 
edges of the fan housing. 

Note: If the cone-shaped rubber pin is too long, use a razor blade to cut the extra 
length. 

5. With the replacement fan installed securely, and the fan connector connected to the 
logic board, reassemble and test the computer. 



PowerBook G4 (1GHz/867MHz) Primary Fan - 3 



PowerBook G4 (lGHz/867MHz) 



Secondary Fan 
Replacement Instructions 



The following instructions explain how to replace the secondary fan in the PowerBook G4 
(1GHz/867MHz) computer. 

Tools 

• Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool 

• Torx T6 screwdriver 

Preliminary Steps 

Before you begin, remove the following: 

• Battery 

• Logic Board (disconnect the fan's connector from the logic board while removing the 
logic board) 



' 2002 Apple Computer, Inc. All rights reserved. 



Procedure 

1 . Remove the T6 screw from the fan bracket. 

2. Disconnect the fan's connector from the logic board while removing the logic board. 
Lift out the fan assembly. 




PowerBook G4 (1GHz/867MHz) Secondary Fan - 2 



PowerBook G4 (lGHz/867MHz) 



PC Card Cage 
Replacement Instructions 



The following instructions explain how to replace the PC card cage in the PowerBook G4 
(1GHz/867MHz) computer. 



Tools 



• Torx T8 screwdriver 

• 4 mm Hex socket or wrench 

• 5 mm Hex socket or wrench 

Preliminary Steps 

Before you begin, remove the following: 

• Battery 

• Keyboard 

• Logic board 



' 2002 Apple Computer, Inc. All rights reserved. 



Procedure 

1 . Remove the two screws that attach the PC card cage to the rib frame. (The longer 
screw is next to the battery connector.) 

2. To remove the 4 mm hex nut that secures the PC card cage to the heat exchanger, 
you may want to use a finger to support the 5 mm (magnetic) hex screw underneath 
the nut to prevent the screw from falling out of the screw hole. 

Loosen and remove the hex nut. Remove the PC card cage, being careful where it 
can catch on the PC card eject button. Then, reattach the hex nut temporarily to the 
hex screw. 




PowerBook G4 (1GHz/867MHz) PC Card Cage - 2 



3. Check that the replacement PC card cage includes a clear plastic shim on the outer 
frame near the PC card eject button. If the shim is not there, transfer the shim from the 
old PC card cage to the replacement PC card cage. 




4. When installing the replacement PC card cage, ensure that the metal flange that is 
closest to the PC card eject button goes underneath the rib frame and metal liner at 
the battery latch. 



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5. Install the replacement PC card cage, and reassemble and test the computer. 



PowerBook G4 (1GHz/867MHz) PC Card Cage - 3 



PowerBook G4 (lGHz/867MHz) 



Rib Frame and Heat Exchanger 
Replacement Instructions 



The following instructions explain how to replace the rib frame and the heat exchanger in 
the PowerBook G4 (1GHz/867MHz) computer. 

Warning: Make sure you carefully follow these instructions, especially when 
working near cables that attach to the display module. If any of the cables are 
damaged, the entire display module must be replaced. 

Tools 

• Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool 

• Torx T8 screwdriver 

• Torx T6 screwdriver 

Preliminary Steps 

Before you begin, remove the following: 
Battery 
Keyboard 

Bottom case (remove in step 2) 
Hard drive 
Optical drive 
Logic board 
PC card cage 
Secondary fan 



' 2002 Apple Computer, Inc. All rights reserved. 



Procedure 

1 . With the display open and the keyboard removed, remove the five identical T8 screws 
from the top case. 




2. Remove the bottom case. 

Important: With the bottom case removed, be careful when turning over the 
computer. Some components could become loose and fall out. 

3. Open the I/O door, and remove the four identical T6 screws. 




4. Lift out the two back panel mounts from the notches in the rib frame. 




PowerBook G4 (1GHz/867MHz) Rib Frame and Heat Exchanger - 2 



5. Close the computer to an approximate 45-degree angle, and stand it on a soft cloth 
with the clutch covers facing up. 

6. Remove the four identical T8 screws from the clutch covers (two screws on each 
clutch cover). 




7. Use a black stick to pry off the two clutch covers. 

Note: Opening the display slightly may help to remove the covers. 




PowerBook G4 (1GHz/867MHz) Rib Frame and Heat Exchanger - 3 



8. Open the computer so that the display rests in your lap and is protected by a soft 
cloth. 

9. Warning: Be especially careful when working near cables that attach to the 
display. If any of these cables are damaged, the entire display module must be 
replaced. 

Warning: At the left clutch, the wrapped cable connected to the LVDS (low 
voltage data signal) connector is extremely delicate. Do not pull or pinch the 
LVDS cable. Do not allow the screwdriver to touch the LVDS cable. 

Locate the two large silver-colored screws. Gently move aside the LVDS cable so 
you can access the screws. 

Remove the two silver-colored T8 screws from the left clutch. Notice that the screw 
closest to the LVDS cable has a sloped screw head. (Do not remove the smaller 
screws.) 

Important: When installing the replacement display, make sure the screw closest to 
the LVDS cable is the screw with the sloped head. 




PowerBook G4 (1GHz/867MHz) Rib Frame and Heat Exchanger - 4 



10. At the right clutch, note the routing of the inverter cable. Without straining the inverter 
cable, gently move it aside so you can access the two large silver-colored screws. 

1 1 . Support the display as you remove the two identical, large, silver-colored T8 screws 
from the right clutch. (Do not remove the smaller screws.) 




12. Important: With the display hinge disconnected, support the display as you place it 
face-down on a soft cloth in front of the computer chassis. 

Warning: Do not separate the display cables from the computer chassis. Do 
not strain the cables. 




PowerBook G4 (1GHz/867MHz) Rib Frame and Heat Exchanger - 5 



13. Remove the four rib frame screw. Three are identical black T8 screws, the forth is a 
longer chrome T8 and also secures the heat exchanger alignment bracket to the end 
of the heat exchanger. (You might need to move aside the AirPort antenna cable to 
reach one of the screws.) 

Replacement Note: Make sure to replace the longer chrome screw through the alignment 
bracket so that it secures the small alignment nub on the end of the heat exchanger. Look 
from the side through the air vents of the top case to verify that the ribs on the heat 
exchanger do not block the vents. 




14. Lift the rib frame off of the heat exchanger. If the heat exchanger sticks to the rib 
frame, press gently on the heat exchanger near the two connection points shown. 



i 



k 




PowerBook G4 (1GHz/867MHz) Rib Frame and Heat Exchanger - 6 



15. Disconnect the audio cable at each end of the heat exchanger. 





PowerBook G4 (1GHz/867MHz) Rib Frame and Heat Exchanger - 7 



1 6. Pivot the heat exchanger out of the top case assembly. Be careful where it might catch 
at the LVDS cable. 

Warning: At the left clutch, the wrapped cable connected to the LVDS 
connector is extremely delicate. Do not pull or pinch the LVDS cable. 

Warning: Do not bend the heat pipe. 





A 



<fc:A 



PowerBook G4 (1GHz/867MHz) Rib Frame and Heat Exchanger - 8 



17. If replacing the rib frame but reusing the heat exchanger, scrape off the thermal 
transfer material residue from the area shown. Apply new thermal transfer material to 
the logic board chip. 




Replacement Notes: If replacing the heat exchanger, transfer the hex nut and screw to 
the replacement heat exchanger. 

When replacing the heat exchanger, check that the audio cable is routed as shown. 




If replacing the rib frame, transfer the battery connector to the replacement rib frame, if 
needed. 

Ensure that a modem filter board cable is attached to the replacement rib frame; if not, 
transfer the cable. The cable should route as shown below. 




<£>' 



© 



v 



* * * + 



Check that the EMI clip for the optical drive's flex cable has been removed for transfer to 
the replacement rib frame. 

18. Install the replacement rib frame and/or heat exchanger, and reassemble and test the 
computer. 



PowerBook G4 (1GHz/867MHz) Rib Frame and Heat Exchanger - 9 



PowerBook G4 (lGHz/867MHz) 



Bulb Wire Cable 
Replacement Instructions 



The following instructions explain how to replace the bulb wire cable in the PowerBook G4 
(1GHz/867MHz) computer. 

Tools 

• Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool 

• Torx T8 screwdriver 



Preliminary Steps 

Before you begin, remove the following: 

• Battery 

• Optical drive 

• Logic board 



' 2002 Apple Computer, Inc. All rights reserved. 



Procedure 

Important: With the bottom case removed, be careful if turning over the computer. Some 
components could become loose and fall out. 

Note: Remove any kapton tape as needed and replace during reassembly. 

1 . Loosen or remove the chrome T8 screw holding the heat exchanger alignment bracket 
and the right side of the rib frame. 

2. Disconnect the bulb wire cable connector. 



Replacement Note: Make sure the alignment bracket secures the small alignment nub on 
the end of the heat exchanger. Look from the side through the air vents of the top case to 
verify that the ribs on the heat exchanger do not block the vents. 

3. Pull up slightly on the rib frame then deroute the bulb wire cable. 

Replacement Note: Route the replacement cable as shown. Use a black stick to tuck the 
cable in over the backup battery cable between the speaker and top case. 



£ 




PowerBook G4 (1GHz/867MHz) Bulb Wire Cable - 2 



Replacement Note: After reconnecting the bulb wire, ensure that the bulb wire cable is 
safely tucked within the case edge so that it will not get pinched by the bottom case. 




4. Reassemble and test the computer. 

Important: Make sure the bottom case is installed correctly. If the slot-load area is 
slightly bowed, carefully pull the bottom edge of the slot until it clicks into place and 
becomes flush with the bottom case. 




Important: Check the operation of the optical drive. If the drive is installed 
incorrectly, the optical drive mechanism might not spin correctly and will result in 
mechanical noise when playing a disc. 



PowerBook G4 (1GHz/867MHz) Bulb Wire Cable - 3 



PowerBook G4 (lGHz/867MHz) 



I/O Door 

Replacement Instructions 



The following instructions explain how to replace the I/O door in the PowerBook G4 
(1GHz/867MHz) computer. 

Tools 

• Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool 

• Needle nose pliers 

Preliminary Steps 

Before you begin, remove the following: 

• Battery 

• Logic board 



' 2002 Apple Computer, Inc. All rights reserved. 



Procedure 

1 . Using needle nose pliers, pull off the rubber plugs at each end of the door. Remove 
the springs, and set aside the plugs and springs. 

Important: Be very careful not to damage or bend the heat exchanger pipes. 




2. Pull the door away from the top case. 




=*J 




! 



3. Remove the L-shaped pin from each end of the I/O door. 



Note: The L-shaped pin has a knob at one end. The knobbed end holds the rubber 
plug onto the L-shaped pin. 




4. Install the replacement I/O door. Make sure each L-shaped pin threads through the 
top case, inner clutch mount, spring, and plug. 

Note: You might need to use a black stick to compress the spring while installing the 
plug on each L-shaped pin. 

5. Reassemble and test the computer. 



PowerBook G4 (1GHz/867MHz) I/O Door - 2 



PowerBook G4 (lGHz/867MHz) 



Display Module 
Replacement Instructions 



The following instructions explain how to replace the display module on the PowerBook G4 
(1GHz/867MHz) computer. 

Warning: Make sure you carefully follow these instructions, especially when 
working near cables that attach to the replacement display module. If any of the 
cables are damaged, the entire display module must be replaced. 

Tools 

• Soft cloth 

• Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool 

Preliminary Steps 

Before you begin, remove the following: 

• Battery 

• DC-ln Board 

• Rib frame and heat exchanger 



' 2002 Apple Computer, Inc. All rights reserved. 



Procedure 

1 . With the rib frame and heat exchanger removed, make sure 

• The display is supported on a soft cloth in front of the top case 

• The display cables are not strained 

Warning: Be especially careful when working near cables that attach to the 
display. If any of these cables are damaged, the entire display module must be 
replaced. 

The LVDS cable and connector are extremely delicate. Do not pull or pinch the 
LVDS cable or connector. If necessary, use a black stick or other 
nonconductive tool to guide the cables out of the top case. 

2. Raise the inner clutch mount so it is pivoted away from the LVDS cable and sleep LED 
cable. 




PowerBook G4 (1GHz/867MHz) Display Module - 2 



3. Thread the 2-pin LED sleep cable through the opening in the top case. 

Carefully guide the LVDS cable through the opening by looping the cable and turning 
the LVDS connector sideways, as shown, to fit through the opening. 




4. At the right clutch, raise the inner clutch mount and disconnect the inverter cable. 
Carefully slide the inverter cable out through the opening in the top case. 




5. The display module includes all three cables. 



PowerBook G4 (1GHz/867MHz) Display Module - 3 




Important: When the replacement display module is installed, and before the clutch 
covers are installed, test that the display is seated properly. With the computer upright 
and closed, press the computer latch. The display module should pop up slightly if the 
module is properly seated. 




7. Install the replacement display module, and reassemble and test the computer. 



PowerBook G4 (1GHz/867MHz) Display Module - 4 



PowerBook G4 (lGHz/867MHz) 



Top Case 
Replacement Instructions 



The following instructions explain how to replace the top case in the PowerBook G4 
(1GHz/867MHz) computer. 

Tools 

• Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool 

• Razor blade (optional) 

Preliminary Steps 

Before you begin, remove the following: 

• Battery 

• Backup battery 

• Display module 

• I/O door 



' 2002 Apple Computer, Inc. All rights reserved. 



Procedure 

1 . With the preliminary steps completed, compare the original top case to the 
replacement top case. 

2. Before installing the replacement top case, make sure it includes the following: 

• Speaker set and cables 

• Power button and board (heatstaked to top case) 

• AirPort antenna cable 

• Trackpad assembly with board and cable 




3. Important: Make sure you transfer the original serial number label from the old top 
case to the serial number panel on the replacement top case. You can use a black 
stick or razor blade to carefully peel up a corner of the label. Then peel off the label 
completely and apply it to the serial number panel. Make sure that the label lies 
completely flat so it does not interfere with the battery compartment. 




PowerBook G4 (1GHz/867MHz) Top Case - 2 



4. Confirm that the thermal strip and mesh liners are installed at the back panel. 




& 5_1 




5. Important: Make sure you transfer the backup battery cable from the original top 
case to the replacement top case. The backup battery cable is tucked below the bulb 
wire cable along and between the speaker and top case, as shown. 




6. Install the replacement top case, and reassemble and test the computer. 



PowerBook G4 (1GHz/867MHz) Top Case - 3 



PowerBook G4 (lGHz/867MHz) 



Exploded View 



Hard Drive Screw 922-4502 
Hard Drive Rubber Stopper 

Hard Drive Flex Cable 922-4378 

AirPortCard 661-2549 

AirPort Card Carrier 

Logic Board 661-1799 (867 MHz) 
661-1800(1 GHz) 

RJ-11 Modem Port 922-5351 

Primary Fan Assembly 922-5459 

Thermal Transfer Material 
922-4626 

Battery Eject Switch Assembly 
922-4634 

Battery Connector Assembly 

922-5046 

Modem Cable 

4mm Hex Nut 

Speaker Wire 

Heat Exchanger with 

speaker wire 922-5445 

5mm Hex Screw 
Modem EMI Filter Board 922-5212 



AirPort Antenna Assembly 922-5340 

I/O Door Assembly 922-5343 
Clutch Cover 922-4635 




Battery 661-2740 



Bottom Case 922-5443 



Hard Drive Mounting Bracket 
076-0946 

Hard Drive 661 -1 801 (40 GB) 
661-1802 (60 GB) 
CD-RW/DVD-ROM (Combo) Drive 
661-2690 

DVD-R/CD-RW (Apple SuperDrive) 
661-1804 

Inverter Board Flex Cable 922-5210 
Inverter Board 922-5204 
Bulb Wire Cable 922-5217 
Modem 661-2687 
Modem Flex Cable 922-5214 

CD-RW/DVD-ROM Flex Cable 
922-5208 

SDRAM 661 -2563 (256 MB) 
661-2564 (512 MB) 

Rib Frame Assembly 922-5206 



Optical Drive Flex Cable EMI Clip 
922-5209 



PC Card Cage 922-4627 



Backup Battery 922-5205 



Top Case 922-5444 



Secondary Fan 922-5564 



DC-ln Board Cable 922-5211 
DC-ln Board 922-5460 

Keyboard 922-5199 



Display Module 661-2748 



' 2002 Apple Computer, Inc. All rights reserved. 



PowerBook G4 (lGHz/867MHz) 



Screw Reference Sheet 



This sheet shows the screws used in the PowerBook G4 (1GHz/867MHz) computer 
and indicates the replacement procedure where first removed. 
To see where the screws are located in the computer, refer to the 
"PowerBook G4 (1GHz/867MHz) Screw Locator." 

© [}B TorxT6, 4.15 mm long: DC- In Board (1) 

Inverter Board (2) 
Modem (2) 

@ QfiS TorxT6, 5.12 mm long: DC-ln Board (1) 

Secondary Fan (DC-ln Board) (1) 

(O) yB TorxT8, 4.4 mm long: Rib Frame and Heat Exchanger (5) 

© Q3 TorxT8, 4.5 mm long: Modem Filter Board(1) 

Logic Board (1) 
AirPort Card Carrier (3) 

© LJa TorxT8 (black), 4.9 mm long: Hard Drive (4) 

{QJ Ha TorxT8, 5 mm long: Logic Board (1) 

© Qa TorxT8, 5.2 mm long: Logic Board (1) 

PC Card Cage (1) 

Rib Frame and Heat Exchanger (4) 

(q) fka TorxT8 (bronze), 6.4 mm long: Logic Board (5) 

© Q=9 TorxT8, 6.5 mm long: PC Card Cage (1) 

(q) yES TorxT8, 8 mm long: Bottom Case (7) 

tsa TorxT8, 9.3 mm long: Hard Drive/Optical Drive 

Hold Down Bracket (2) 



© QcSQ Torx T8 (black), 9.5 mm long: Rib Frame and Heat Exchanger (3) 

© [}ssa TorxT8 (chrome), 10 mm long: Rib Frame and Heat Exchanger Alignment Bracket(1) 

to) HKS TorxT8, 16 mm long: Rib Frame and Heat Exchanger (1) 

to) uS^^ TorxT8, 16.75 mm long: Rib Frame and Heat Exchanger (3) 

4 mm Hex Nut: PC Card Cage (1 ) 



O 



<Q> ^ 5 mm Hex Screw, magnetic: PC Card Cage (1) 



' 2002 Apple Computer, Inc. All rights reserved. 



PowerBook G4 (lGHz/867MHz) 



Screw Locator 



Bottom Case 



© 

Seven identical Torx T8, 
8 mm long 




Hard Drive and Optical 
Drive Hold Down Bracket 



Two identical Torx T8, 
9.3 mm long 



Hard Drive 

© Da 

Four identical (black) Torx T8, 
4.9 mm long 




Modem Filter Board 



One Torx T8, 4.5 mm long 




' 2002 Apple Computer, Inc. All rights reserved. 



Secondary Fan 

OneTorxT6, 5.12 mm long 




DC-ln Board 

@ Qd 

OneTorxT6, 4.15 mm long 

@ Qa 

(A) - OneTorxT6, 5.12 mm long 




Inverter Board 



® 



TwoTorxT6, 4.15 mm long 




Modem 

@ Qq 

TwoTorxT6, 4.15 mm long 




PowerBook G4 (1GHz/867MHz) Screw Locator - 2 



Logic Board 



Qa 



One Torx T8, 4.5 mm long 



® 



(A) - One Torx T8, 5 mm long 

@ Qa 

(B) - One Torx T8, 5.2 mm long 



© 



Five identical Torx T8, 
6.4 mm long (bronze) 




® [}a 

Three Torx T8, 4.5 mm long 




PowerBook G4 (1GHz/867MHz) Screw Locator - 3 



PC Card Cage 

(A) - One Torx T8, 5.2 mm long 

©Lmmmaamaaaa 

(B) - One TorxT8, 6.5 mm long 



o> 



(C) - One 4 mm Hex Nut 

o 




One 5 mm Hex Screw, magnetic, (accessed from keyboard opening) 



Rib Frame and Heat Exchanger 



© 



Five identical Torx T8, 
4.4 mm long 




muwwaw 

Four identical Torx T8, 
5.2 mm long 




© 



(A) -One Torx T8, 
16.75 mm long 



®> 



(B)- One Torx T8, 
16 mm long 




PowerBook G4 (1GHz/867MHz) Screw Locator - 4 



Rib Frame and Heat Exchanger (continued) 



© 



Two identical Torx T8, 
16.75 mm long 



Three identical (Black) 
TorxT8, 9.5 mm long 

(A) - One (Chrome) Torx T8 
10 mm long 




PowerBook G4 (1GHz/867MHz) Screw Locator - 5 



I Service Source 




Troubleshooting 



PowerBook G4 (lGHz/867MHz) 



© 2002 Apple Computer, Inc. All rights reserved. 




Symptom Charts 



How to Use the Symptom Charts 

The Symptom Charts included in this chapter will help you diagnose specific 
symptoms related to the product. 

The steps to solve a symptom are listed sequentially. You might not need to 
perform every step before the symptom is solved. Start with the first step, and 
then test for the symptom. If the symptom persists, replace any modules you 
removed, go to the next step, and test again. Continue down the list until the 
symptom is solved. 

Note: Software install and restore procedures are new for the PowerBook G4 
(1GHz/867MHz). For new procedures, refer to the read me files that came with 
the software install and restore DVD disc for the PowerBook G4 (1 GHz/867MHz). 

Related articles can be found in the Knowledge Base at: 
http://kbase.info.apple.com/ 

Startup 

The computer will not power on (no fan movement, hard drive spin up and 
display is not lit) 

1 . Remove any connected peripherals. 

2. Check that the battery has enough charge to start the computer by pressing the button 
next to the LEDs on the battery. At least one LED must light solid (not flashing). 

3. Connect known-good PowerBook (1 GHz/867MHz) power adapter (661 -1 798) and 
power cord or plug to a known-good power outlet; make sure the DC plug is firmly 
inserted. The DC plug should light up, if not, replace DC-in board. 

Important: The PowerBook (1GHz/867MHz) power adapter must be used with the 
PowerBook (1GHz/867MHz) computers. The adapters can be identified by 65W in 
the name and markings, and the metal securing-stud on the plug connector. 

4. Try powering up without the battery installed. 

5. Press Caps Lock key to see if light on key comes on. If it does, hold power button 
down for six seconds to shut down the computer and restart. 



Startup Symptom Charts PowerBook G4 (1GHz/867MHz) Troubleshooting - 1 



6. With a non-metallic tool, reset the power manager by pressing the reset button 
(located under the keyboard in the recess just left of the power button). Wait five 
seconds before continuing. Press the power button to start the computer. 

Warning: Resetting the power manager will permanently remove a RAM disk, if 
present, and all of its contents. You will also need to reset the date and time 
(using the Date &Time control panel) 




7. Verify power button cable is connected properly to logic board, if power button is not 
functioning correctly or damaged, replace the top case. 

8. Disconnect keyboard completely. Inspect connectors. Restart with keyboard 
disconnected. 

9. Remove any additional RAM. 

10. Remove AirPort Card. 

1 1 . Verify DC-in board cable is securely connected. 

12. Try known-good DC-in board. 

13. Replace logic board. 

Memory error message appears on the screen 

1. Reseat the DIMMs. 

2. Verify proper memory is being used. The PowerBook (1GHz/867MHz) uses 1.25- 
inch (or shorter) PC-133 compliant, SO-DIMM memory cards. 

3. Run Apple Hardware Test. If the test finds bad memory, replace the DIMMs one at a 
time and test until all bad DIMMs are replaced with known-good modules. If the failure 
is intermittent, run Apple Hardware Test in loop mode (Control-L) for an extended time 
to test the memory. 



Startup Symptom Charts 



PowerBook G4 (1GHz/867MHz) Troubleshooting - 2 



Flashing question mark appears on the screen 

1 . Start up from the software install and restore disc that came with the computer (hold 
down the "C" key during restart). 

2. When the Installer opens, from the Installer menu, select Open Disk Utility. 

3. If the hard drive is recognized, under the First Aid tab verify the hard disk, and repair if 
needed. Restart the computer. 

4. If the hard drive is not recognized, reseat the hard drive flex cable. If still not 
recognized, replace the hard drive. 

5. Reinstall system software using the software install and restore disc. 

Computer begins to power up, the fan and hard drive are spinning, hitting 
caps lock key and LED turns on, but there is no startup chime or video 

1 . With a non-metallic tool, reset the power manager by pressing the reset button 
(located under the keyboard in the recess just left of the power button). Wait five 
seconds before continuing. Press the power button to start the computer. 

Warning: Resetting the power manager will permanently remove a RAM disk, if 
present, and all of its contents. You will also need to reset the date and time 
(using the Date &Time control panel). 




2. Replace the logic board. 

System shuts down intermittently 

1 . Disconnect all external peripherals. 

2. Make sure the battery is fully inserted and is charged. 

3. Check battery connection to main logic board. 

Startup Symptom Charts PowerBook G4 (1 GHz/867MHz) Troubleshooting - 3 



4. Make sure system is not over heating, the air vents are clear and unit is not on soft 
surface. 

5. Check that the fan cable is connected and the fan is operational. 

6. Check that the heat exchanger is properly attached to the processor. 

Important: If the heat exchanger is separated from the logic board, new thermal 
transfer material for the processor must be reinstalled. 

7. Remove the battery and connect known-good PowerBook (1GHz/867MHz) power 
adapter (661-1798) and power cord or plug to a known-good power outlet; make sure 
the DC plug is firmly inserted. The DC plug should light up, if not, replace DC-in board. 

Important: The PowerBook (1GHz/867MHz) power adapter must be used with the 
PowerBook (1GHz/867MHz) computers. The adapters can be identified by 65W in 
the name and markings, and the metal securing-stud on the plug connector. 

8. Verify DC-in board cable is securely connected. 

9. Try known-good DC-in board. 

10. Replace the logic board. 

System shuts down almost immediately after startup 

1 . Disconnect all external peripherals. 

2. Make sure the battery is fully inserted and is charged. 

3. Check battery connection to main logic board. 

4. Replace the logic board. 

System crashes or hangs intermittently 

1 . If the system crashes or hangs in a specific application, replace the application. Mac 
OS X: Verify the application is compatible with OS X. 

2. Clear parameter RAM. Hold down Command-Option-P-R during startup until you hear 
a second startup chime. 

3. Perform a clean install of system software with the software install and restore disc 
that came with the computer. 

4. Mac OS 9: Start up with extensions off to determine if there are system extension or 
control panel problems. 

5. Mac OS X: Relaunch Finder. 

6. Mac OS X: Run Disk Utility. Mac OS 9: Run Disk First Aid. 

7. Run Apple Hardware Test in loop mode (Control-L) for an extended time to test the 
memory. If the test finds bad memory, replace the DIMMs one at a time and test until 
all bad DIMMs are replaced with known-good modules. 

8. Replace the logic board. 

Startup Symptom Charts PowerBook G4 (1GHz/867MHz) Troubleshooting - 4 



At startup, a dialog box comes up stating: "kernel panic" in Mac OS X or 
"Built-in memory test has detected an error" in Mac OS 9 

1 . If there are two RAM cards installed in the expansion slots, remove top card and 
restart. 

• If symptom repeats, replace bottom card with known-good RAM card. 

• If symptom does not repeat, replace top RAM card with known-good RAM 
card and restart. 

Error Beeps 

The computer automatically performs a power-on self test when it is turned on 
after being fully shut down (not a restart). This section describes what to do if 
beeps are heard during the startup. 

Note: The PowerBook G4 has two memory expansion slots and accepts 1.25-inch 
(or shorter) PC-133 compliant, SO-DIMM memory cards; there is no RAM on 
the logic board itself. Refer to Memory Card Replacement instructions for 
removal and installation. 

Computer beeps once at startup 

1 . One beep means that no RAM is detected. 

Note: There is no RAM on the logic board itself, so the computer will beep if no 
memory is installed in at least one of the RAM slots. 

2. Put the original RAM that came with the computer back in, or put in known-good and 
compatible RAM and restart. 

• If symptom does not repeat, replace RAM card(s). 

• If symptom repeats, replace logic board. 

Computer beeps twice at startup 

1 . Two beeps means that EDO memory is installed in the RAM expansion slot. The 
PowerBook does not accept EDO memory. 

2. Replace RAM card(s) with known-good and compatible RAM and restart. 

• If symptom repeats, replace logic board. 

Computer beeps three times at startup 

1 . Three beeps means that no RAM banks passed memory testing. 

2. If a RAM card is installed in the upper expansion slot (if not, skip to next step), remove 
it and restart. 

• If symptom does not repeat, replace RAM card. 

• If symptom repeats, replace RAM in lower RAM slot with known-good and 
compatible RAM card and restart. If symptom repeats, replace logic board. 



Error Beeps Symptom Charts PowerBook G4 (1GHz/867MHz) Troubleshooting - 5 



3. If a RAM card is not installed in the upper expansion slot, replace RAM in lower RAM 
slot with known-good and compatible RAM card and restart. 

• If symptom repeats, replace logic board. 

Computer beeps four times at startup 

1 . Four beeps indicates a bad checksum for the remainder of the boot ROM. The ROM 
(which is located on the logic board) is bad. 

2. Replace RAM card(s) with known-good and compatible RAM and restart. 

• If symptom repeats, replace logic board. 

Related articles: 

58442: Power On Self-Test Beep Definition - Part 2 

95132: PowerBook G4: Installing or Replacing Memory 

AirPort Card 

AirPort Card not recognized 

1 . In Mac OS X, use Software Update in System Preferences, or in Mac OS 9 use the 
Software Update control panel, or see the Apple Software Updates web page to make 
sure the latest version of AirPort software is installed. 

2. Restart the computer. Mac OS 9: Restart using Mac OS All extensions setting. 

3. Mac OS X: Open AirPort in System Preferences and make sure AirPort is on and 
Base Station is selected. Mac OS 9: Open Airport in Apple Menu and make sure 
AirPort is on and Base Station is selected. 

4. Reseat AirPort Card and make sure AirPort antenna cable is fully connected. 

5. Remove and reinstall the AirPort software. 

6. Replace with known-good AirPort Card. 

7. Replace logic board. 

Battery 

Battery will not eject 

1 . Flip over the unit and release the battery latch by sliding the latch towards the PC 
Card button. 

2. If the battery still will not eject, while holding the latch towards the PC Card button, use 
a small plastic flat-blade tool to pry the battery around the battery latch. 

3. Verify proper latch operation, by exercising the latch. If it does not move smoothly or 
evenly, replace the latch. 

4. If the latch does exercise correctly, verify that the customer is not installing the battery 
with excessive force. 

AirPort Card Symptom Charts PowerBook G4 (1GHz/867MHz) Troubleshooting - 6 



The battery won't charge 

1 . Remove any externally connected peripherals. 

2. Try known-good power outlet. 

3. Connect known-good PowerBook (1 GHz/867MHz) power adapter (661 -1 798) and 
power cord or plug; make sure the DC plug is firmly inserted. The DC plug should light 
up, if not, replace DC-in board. 

If the power adapter light is green, turn over the computer and press the battery 
button. The battery lights should glow green and stay on if the power adapter is 
operating correctly. 

Important: The PowerBook (1GHz/867MHz) power adapter must be used with the 
PowerBook (1GHz/867MHz) computers. The adapters can be identified by 65W in 
the name and markings, and the metal securing-stud on the plug connector. 

4. Try known-good battery. 

5. Turn off the computer. With a non-metallic tool, reset the power manager by pressing 
the reset button (located under the keyboard in the recess just left of the power 
button). Wait five seconds before continuing. Press the power button to start the 
computer. 

Warning: Resetting the power manager will permanently remove a RAM disk, if 
present, and all of its contents. You will also need to reset the date and time 
(using the Date &Time control panel). 




6. Replace DC-in board. 

7. Replace logic board. 



Battery Symptom Charts 



PowerBook G4 (1GHz/867MHz) Troubleshooting - 7 



Hard Drive 

Internal hard drive will not initialize 

If in Mac OS X: 

1 . Start up from the software install and restore disc that came with the computer (hold 
down the "C" key during restart). 

2. When the Installer opens, from the Installer menu, select Open Disk Utility. 

3. If the hard drive is recognized, format it under the Erase tab. 

4. If the hard drive is not recognized, reseat or replace if needed, the hard drive flex 
cable. 

5. If still not recognized, replace the hard drive. 

6. Reinstall system software using the software install and restore disc. 

If in Mac OS 9: 

1 . Launch Drive Setup and update hard drive driver. 

2. If the hard drive is not recognized in Drive Setup, reseat or replace if needed, the hard 
drive flex cable. 

3. If still not recognized, replace hard drive. 

Important: If the computer is under warranty and data recovery is required, refer 
to Article 31077: Hard Drive Data Recovery & Warranty Implications, for 
important information. 

Keyboard 

No response from any key on keyboard 

1 . Remove any connected peripherals. 

2. Turn off the computer. Disconnect the keyboard connector and inspect connectors. 

3. Start up from the software install and restore disc that came with the computer (hold 
down the "C" key during restart) to verify that it is not a software problem. 

4. Replace keyboard. 

5. Replace logic board. 

The keyboard lock is damaged or won't lock 

1 . Verify that keyboard is installed properly so the lock lines up with the notch in the top 
case. 

2. Replace keyboard. 

Hard Drive Symptom Charts PowerBook G4 (1GHz/867MHz) Troubleshooting - 8 



Modem 

No modem dial tone 

1 . Check that the correct modem is selected. In Mac OS X, check Network Setup. In Mac 
OS 9, check the Modem control panel. 

2. Verify known-good analog (not digital) telephone line. 

3. Verify known-good RJ1 1 telephone cable. 

4. Verify RJ1 1 cable is not plugged into Ethernet port. 

5. Inspect RJ1 1 connector and modem port for pin damage. 

6. Verify RJ1 1 telephone cable is firmly installed in the modem port. 

7. If using Apple Remote Access, select Ignore Dial Tone in the Modem control panel. If 
the modem connects with this settings selected, try another phone line. If using a 
terminal or communications program, enter atxl to disable tone detection. To reset the 
modem back to the factory settings, enter atz. 

8. Check RJ-1 1 wires to modem filter board. 

9. Verify modem wire's 2-pin connectors are plugged into modem and modem filter 
board correctly. 

10. Check modem wire. If damaged, replace rib frame and modem cable assembly. 

1 1 . Replace modem filter board. 

12. Replace modem. 

Modem does not respond (gets dial tone) 

1 . Check software. 

2. Replace modem. 

Optical Drive 

The optical drive does not accept CD or DVD disc (mechanical failure) 

1 . Verify disc is not warped and is a 1 2 cm circular disc. 

2. Verify disc is pushed almost all the way into the slot. 

3. Check the optical drive flex cable. 

4. Replace optical drive. 



Modem Symptom Charts PowerBook G4 (1GHz/867MHz) Troubleshooting - 9 



The disc icon does not show up on desktop, or a dialog box appears to 
initialize disc, when inserting a read-only disc 

1 . Verify the correct type of disc is being used. 

2. Note: Some brands of 24x or 32x CD-R media may not work with the SuperDrive. 
Try a different brand or speed of CD-R disc. 

3. Use Software Update control panel to update firmware. 

4. Try cleaning the disc. If it is dirty or scratched, it may not mount. 

5. Try a different disc. 

6. Select "Mac OS All" in the Extensions Manager control panel and restart. 

7. Replace optical drive cable. 

8. Replace optical drive. 

PC Card 

PC Card will not insert into the PC Card slot 

1 . Make sure the PC Card eject button is in, before attempting to insert a PC Card. 




2. Make sure the PC Card is right side up (cards are keyed and cannot be inserted 
upside down). 

3. Verify the PC Card is not warped or damaged in any way; if so replace the card. 

4. Try a different PC Card. 

5. Carefully raise the PC Card slot cover and check for a foreign object inside the slot. 

6. Check to see if the AirPort Card antenna wire is protruding up into the PC Card slot 
opening from below. If so, open the computer to gain access to the AirPort Card 
location and reposition the antenna cable so that it does not sag down into the PC 
Card slot area (see AirPort Card Installation Instructions). 

7. If the slot cover is preventing the card from being inserted, replace the top case. 

8. Replace PC Card Cage. 



PC Card Symptom Charts PowerBook G4 (1GHz/867MHz) Troubleshooting - 10 



Ports 

The Fire Wire or USB port is not recognizing devices 

1 . Completely shut down, then press the power button to start the computer. 

2. Use Software Update in Mac OS X system preferences (or the Software Update 
control panel in Mac OS 9) to verify that the latest software is installed. 

3. Use Apple System Profiler to verify that the computer is recognizing the bus. 

4. For USB, test ports with an Apple keyboard or mouse. 

5. For FireWire, test by connecting another computer in FireWire Target Disk Mode. 
Refer to article 58583: How to Use FireWire Target Disk Mode. 

6. Verify that drivers are installed properly for third party, if needed. 

7. If in Mac OS 9, boot with Mac OS All extension set. 

8. Try a different cable. 

9. If self powered make sure that the power supply is connected and device's LED 
indicates that it is getting power. 

10. Replace logic board. 

A USB device not recognized by computer 

Note: If you are trying to use a serial device with a USB/Serial adapter, check 
with the manufacturer of the adapter for compatibility. 

1 . Completely shut down, then press the power button to start the computer. 

2. Try known-good Apple USB keyboard or mouse to verify the port is working properly. 

3. Verify current driver for the device is installed. 

4. If a camera, turn on camera after initiating download with camera application. 

5. Try the other USB port. 

6. Try different USB device on same port. 

7. Eliminate chain by plugging in only one peripheral. 

8. If in Mac OS 9, select "Mac OS AN" in the Extensions Manager control panel and 
restart. 

9. If in Mac OS 9, troubleshoot extensions and perform a clean installation of system 
software. 

10. Replace logic board. 



Ports Symptom Charts PowerBook G4 (1 GHz/867MHz) Troubleshooting - 1 1 



Sound 

No sound heard and the Speakers section of the Sound control panel indicates 
that an external device is plugged in (to the headphone jack or USB ports) 

1 . If there is nothing plugged into the headphone jack or USB ports, the picture in the 
Speakers section of the Sound control panel should be of the internal speakers, as 
shown here. 



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2. If not, and if nothing is plugged in, try plugging in headphones or external speakers. 
Restart the computer. Remove the device. 

3. Reset PRAM (Press the power button, then hold down the Option-Command-P-R 
keys until you hear the startup chime at least one additional time after the initial 
startup chime). 

Warning: Resetting the PRAM will permanently remove a RAM disk, if present, 
and all of its contents. You will also need to reset the date and time (using the 
Date &Time control panel). 

4. Replace logic board. 

No sound from speaker(s) 

1 . Use the Software Update control panel to verify that the latest audio update has been 
installed. 

2. Press the F3 key (with the fn key pressed and not pressed) to verify that mute mode is 
not enabled. 

3. Press the F4 or F5 key (with the fn key pressed and not pressed) to check the volume 
setting. 

4. Verify no external speakers or headphones are plugged in. 

5. Check the speakers tab on the Sound control panel to confirm that the software is 
correctly seeing that there are no external speakers or headphones connected. 

6. Shutdown computer and restart. 



Sound Symptom Charts PowerBook G4 (1GHz/867MHz) Troubleshooting - 12 



7. Reset PRAM (Press the power button, then hold down the Option-Command-P-R 
keys until you hear the startup chime at least one additional time after the initial 
startup chime). 

Warning: Resetting the PRAM will permanently remove a RAM disk, if present, 
and all of its contents. You will also need to reset the date and time (using the 
Date &Time control panel). 

8. Verify that the speaker cable is connected properly to logic board. 

9. Check speaker cable. Verify left and right cable connections. 

10. Check with headphones or external speaker, if audio is heard, replace heat exchanger 
with speaker wire assembly. 

1 1 . Replace top case. 

12. Replace logic board 

Distorted sound from speakers 

1 . Verify sound is correct with external speakers/headphones. If sound is correct, check 
speaker wire and connections. 

2. In Mac OS X check balance. 

3. Compare same sound with two different units to make sure that sound is actually 
distorted. 

4. Check speaker wire. If damaged, replace heat exchanger with speaker wire assembly. 

5. Replace top case. 

6. Replace logic board. 

Video 

No display, or dim display, but computer appears to operate correctly 

1 . Remove any connected peripherals. 

2. Make sure F1 key is not stuck down. 

3. Press the F2 key (with the fn key pressed and not pressed) to increase the screen 
brightness settings. 

4. Reboot the computer — hold down the Control and Command keys and press the 
Power button to restart the computer. Or, press and hold the Power button for 5 to 10 
seconds to shut down the computer, then press the Power button to restart. 

5. Make sure using the PowerBook (1 GHz/867MHz) power adapter (661 -1 798) 

6. Verify inverter flex cable and LVDS cable connections are seated properly and that the 
cables are not damaged (refer to inverter board and display module replacement 
instructions). 

Video Symptom Charts PowerBook G4 (1GHz/867MHz) Troubleshooting - 13 



7. Replace inverter board. 

8. Replace display assembly. 

9. Replace logic board. 

Computer appears to work, but no video on external device connected to the 
TV out port (S-video out port) 

1 . The device must be connected to the S-video port while the PowerBook is sleeping or 
off for the device to be recognized. 

2. If running Mac OS X, verify that this issue is also in Mac OS 9. 

3. Verify monitor that is used in testing is known-good and is supported by this computer. 

4. Try different cable(s). 

5. Replace logic board. 

No video on an external VGA device connected to the external monitor (DVI- 
I) port 

1 . In the Resolution control strip, see if the device is being recognized. If so select 
resolution. 

2. If running Mac OS X, verify that this issue is also in Mac OS 9. 

3. Verify monitor that is used in testing is known-good and is supported by this computer. 

4. Try another DVI-to-VGA adapter cable. 

5. Restart the computer and test again. 

6. Replace logic board. 

Misc. Symptoms 

Latch not working 

Note: When the display is being closed, a hook in the top of the display housing 
should be magnetically pulled down to the latch. When the latch button is pushed, 
the hook should release and retract into the display housing. 

1 . Verify hook operation by exercising the latch mechanism. 

2. If the hook does not operate properly, replace the display assembly. 

3. If the latch or latch button does not operate properly, replace the top case assembly. 



Misc. Symptoms Symptom Charts PowerBook G4 (1GHz/867MHz) Troubleshooting - 14 



The Date and Time settings reset all the time 

Note: Resetting the power manager or PRAM resets the date and time. 

1 . Do a backup battery test: 

• Set the date and time. 

• Perform a Shut Down from the Apple menu or Special menu. 

• Remove the main battery and disconnect the power adapter for 10 minutes. 

• Connect the power adapter, insert the battery, and power on the computer. 

• If the date and time were lost the backup battery may be dead or discharged. 

• Remove the main battery from the unit and leave the PowerBook plugged in 
for at least 5 hours. 

Note: If a discharged main battery is installed in the computer, recharging the 
backup battery may take up to 48 hours to completely charge. It is okay to use 
it while it is charging. 

• If the date and time still reset, replace the backup battery. 

2. If not the backup battery, replace logic board. 

Note: For main and backup battery part numbers, refer to article 1 1 751 : 
Macintosh Family: Batteries and Part Numbers. 

AirPort Card installed and received a -3278 error 

1 . Use Software Update control panel or see the Apple Software Updates web page to 
make sure the latest version of AirPort software is installed. 

2. Boot using Mac OS All extensions setting. 

3. Reseat AirPort Card. 

4. Remove and reinstall the AirPort software. 

5. Replace with known-good AirPort Card. 

6. Replace logic board. 

The microphone is not working 

1 . Check the Sound control panel and verify that the selection for input is the built-in 
microphone. 

2. Check the signal level and level meter and adjust the gain. 

3. Remove Sound Preferences from the Preferences folder and restart. 

4. Reset PRAM (Press the power button, then hold down the Option-Command-P-R 
keys until you hear the startup chime at least one additional time after the initial 
startup chime). 

Warning: Resetting the PRAM will permanently remove a RAM disk, if present, 
and all of its contents. You will also need to reset the date and time (using the 
Date &Time control panel). 

Misc. Symptoms Symptom Charts PowerBook G4 (1GHz/867MHz) Troubleshooting - 15 



5. If no sound as well as microphone is not working, verify cable connections. 

6. Replace top case. 

During startup boot sequence and before reaching Finder, the following 
dialog box appears: "The built-in memory test has detected an error" 

1 . If a RAM card is installed in the upper expansion slot (if not, skip to next step), remove 
it and restart. Refer to Memory Card Replacement instructions. 

• If symptom does not repeat, replace RAM card. 

• If symptom repeats, replace RAM in lower RAM slot with known-good 
SDRAM SO-DIMM RAM card and restart. 

- If symptom repeats, replace logic board. 

2. If a RAM card is not installed in the upper expansion slot, replace RAM in lower RAM 
slot with known-good SDRAM SO-DIMM RAM card and restart. Refer to Customer- 
Installable-Parts Memory Replacement instructions. 

• If symptom repeats, replace logic board. 



Misc. Symptoms Symptom Charts PowerBook G4 (1GHz/867MHz) Troubleshooting - 16